Composite structure fabrication systems and methods

ABSTRACT

Composite structure fabrication systems and methods. The systems include a plurality of ply carriers, each of which is configured to support at least one ply segment, and an elongate forming mandrel, which defines an elongate ply forming surface that is shaped to define a surface contour of the composite structure. The systems further include a carrier transfer device, which is configured to selectively convey a selected ply carrier from a ply kitting area to an intermediate location, and a forming machine, which is configured to deform the selected ply carrier and a respective ply segment over a selected portion of the elongate ply forming surface. The forming machine further is configured to separate the selected ply carrier from the respective ply segment and return the selected ply carrier to the carrier transfer device. The methods include methods of operating the systems.

FIELD

The present disclosure relates to composite structure fabricationsystems and methods.

BACKGROUND

Fabrication of large composite structures, such as aircraft, often mayinvolve kitting, layup, assembly, and/or curing of elongate compositestructures that may be many tens, or even hundreds, of feet long.Fabrication of such elongate composite structures presents uniquemanufacturing challenges.

Traditional manufacturing methods for fabricating composite structuresinclude manually locating a plurality of plies of composite material ona layup mandrel to produce and/or define a composite layup. Thecomposite layup subsequently is cured, on the layup mandrel, to produceand/or define the composite structure. While such traditionalmanufacturing methods may be effective at producing smaller compositestructures, they may be inefficient when applied to producing largercomposite structures. As an example, a manufacturing floor space neededto fabricate large composite structures utilizing traditionalmanufacturing methods may be substantial. As another example, an amountof time required to fabricate large composite structures utilizingtraditional manufacturing methods may be quite large.

Either of these manufacturing constraints may increase the cost offabrication of the large composite structure. Thus, there exists a needfor improved composite structure fabrication systems and methods.

SUMMARY

Composite structure fabrication systems and methods are disclosedherein. The systems include a plurality of ply carriers, each of whichdefines a ply support surface that is configured to support at least oneply segment. The systems also include an elongate forming mandrel thatdefines an elongate ply forming surface that is shaped to define asurface contour of the composite structure. The elongate ply formingsurface also is configured to receive a plurality of ply segments todefine a plurality of plies of composite material. The plurality ofplies of composite material at least partially defines the compositestructure. The systems further include a carrier transfer device, whichis configured to selectively convey a selected ply carrier from a plykitting area to an intermediate location. The systems also include aforming machine, which is configured to receive the selected ply carrierat the intermediate location and to deform the selected ply carrier anda respective ply segment over a selected portion of the elongate plyforming surface. The forming machine further is configured to separatethe selected ply carrier from the respective ply segment and to returnthe selected ply carrier to the carrier transfer device. The systems mayinclude a controller that is programmed to control operation of thecarrier transfer device and the forming machine.

The methods include methods of fabricating a composite structure and/ormethods of operating the systems. The methods include conveying aselected ply carrier from a ply kitting area to a selected locationalong a length of an elongate forming mandrel. The elongate formingmandrel defines an elongate ply forming surface that is shaped to definea surface contour of the composite structure. The elongate formingmandrel further is configured to receive a plurality of ply segments todefine a plurality of plies of composite material. The plurality ofplies of composite material at least partially defines the compositestructure. The methods further include translating a forming machinealong the length of the elongate forming mandrel to the selectedlocation and receiving the selected ply carrier with the formingmachine. The methods also include deforming the selected ply carrier anda respective ply segment over a selected portion of the elongate plyforming surface with the forming machine. The respective ply segment issupported by the selected ply carrier during the deforming. The methodsfurther include releasing the respective ply segment from the selectedply carrier while retaining the respective ply segment on the selectedportion of the elongate ply forming surface. The methods also includereturning the selected ply carrier to the ply kitting area with theforming machine. The methods further include repeating the conveying,the translating, the receiving, the deforming, the releasing, and thereturning with a plurality of ply carriers to locate the plurality ofply segments on the elongate ply forming surface and at least partiallyproduce and/or define an uncured composite structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an example of an aircraft that includes a composite structurethat may be produced using the systems and methods according to thepresent disclosure.

FIG. 2 is an example of a wing that may form a portion of the aircraftof FIG. 1.

FIG. 3 is a schematic representation of a composite structurefabrication system according to the present disclosure.

FIG. 4 is a less schematic top view of a composite structure fabricationsystem according to the present disclosure.

FIG. 5 is a less schematic profile view of a composite structurefabrication system according to the present disclosure.

FIG. 6 is a less schematic view of a portion of a ply kitting areaaccording to the present disclosure.

FIG. 7 is a less schematic view of a portion of a ply kitting areaaccording to the present disclosure.

FIG. 8 is a less schematic view of a portion of a ply kitting areaaccording to the present disclosure.

FIG. 9 is a less schematic view of a carrier transfer device receiving aply carrier from a ply carrier magazine, according to the presentdisclosure.

FIG. 10 is a less schematic view of a plurality of ply carriersaccording to the present disclosure.

FIG. 11 is a less schematic view of a carrier transfer device conveyinga ply carrier along an elongate forming mandrel and to a formingmachine, according to the present disclosure.

FIG. 12 is a less schematic view of a forming machine receiving a plycarrier from a carrier transfer device, according to the presentdisclosure.

FIG. 13 is a less schematic view of a carrier transfer device conveyinga ply carrier along an elongate forming mandrel and from a formingmachine, according to the present disclosure.

FIG. 14 is a less schematic view of an uncured composite transfer deviceremoving an uncured composite structure from an elongate formingmandrel.

FIG. 15 is flowchart depicting methods, according to the presentdisclosure, of fabricating a composite structure.

FIG. 16 is a flow diagram of aircraft production and servicemethodology.

FIG. 17 is a block diagram of an aircraft.

DESCRIPTION

FIGS. 1-15 provide examples of composite structure fabrication systems18, according to the present disclosure, of methods 300, according tothe present disclosure, and/or of composite structures 800 and/oruncured composite structures 810 that may be produced and/or fabricatedutilizing systems 18 and/or methods 300. Elements that serve a similar,or at least substantially similar, purpose are labeled with like numbersin each of FIGS. 1-15, and these elements may not be discussed in detailherein with reference to each of FIGS. 1-15. Similarly, all elements maynot be labeled in each of FIGS. 1-15, but reference numerals associatedtherewith may be utilized herein for consistency. Elements, components,and/or features that are discussed herein with reference to one or moreof FIGS. 1-15 may be included in and/or utilized with any of FIGS. 1-15without departing from the scope of the present disclosure.

In general, elements that are likely to be included in a given (i.e., aparticular) embodiment are illustrated in solid lines, while elementsthat are optional to a given embodiment are illustrated in dashed lines.However, elements that are shown in solid lines are not essential to allembodiments, and an element shown in solid lines may be omitted from agiven embodiment without departing from the scope of the presentdisclosure.

FIG. 1 is an example of an aircraft 700 that includes a compositestructure 800 that may be at least partially constructed utilizingsystems 18 and/or methods 300, according to the present disclosure. FIG.2 is an example of a wing 740 that may form a portion of aircraft 700.Aircraft 700 may include a plurality of components, including anairframe 710, a fuselage 720, a fuselage barrel 730, wing 740, and/or astabilizer 750.

Composite structure 800 of aircraft 700 may include a plurality of plies90 of composite material, which may form a portion of any suitablecomponent of aircraft 700. As an example, and as illustrated in FIG. 1,aircraft 700 may include skin segments 790 that may form, cover, and/orbe an outer surface of any suitable portion of aircraft 700 and/or aplurality of stringers 770 that, together with a plurality of frames780, may support an inner surface of skin segments 790. As anotherexample, and as illustrated in FIG. 2, wing 740 may include a pluralityof wing stringers 742, which may extend along a length of the wing. Wing740 also may include a plurality of ribs 744. Wing stringers 742 andribs 744 together may form and/or define at least a portion of an innersupport structure 746 for wing 700, which may support an inner surface748 of skin segments 790 that cover wing 740. These skin segments alsomay be referred to herein as wing skin segments 790. It is within thescope of the present disclosure that skin segments 790 (or wing skinsegments 790), stringers 770, frames 780, wing stringers 742, ribs 744,and/or inner support structure 746 may be at least partially, or evencompletely, produced from plies 90 of composite material.

FIG. 3 is a schematic representation of a composite structurefabrication system 18, according to the present disclosure. Compositestructure fabrication system 18 also may be referred to herein as afabrication system 18, an elongate composite structure fabricationsystem 18, and/or a system 18.

As illustrated in solid lines in FIG. 3, system 18 includes a pluralityof ply carriers 20, an elongate forming mandrel 32, a carrier transferdevice 40, and a forming machine 50. Each ply carrier 20 includes and/ordefines a ply support surface 22, which is configured to at leasttemporarily support one or more ply segments 92. Ply segments 92 may becreated from a composite material and may be laid-up, built-up, located,placed, and/or layered on elongate forming mandrel 32 to produce and/ordefine an uncured composite structure 810, which may be cured to producea composite structure 800, as discussed in more detail herein. Elongateforming mandrel 32 may have and/or define an elongate ply formingsurface 34. Elongate ply forming surface 34 is shaped to define asurface contour of composite structure 800 and is configured to receiveand/or support a plurality of ply segments 92. System 18 optionally mayinclude additional structures, components, and/or features and/or mayperform additional functions, as discussed in more detail herein.

During operation of system 18, carrier transfer device 40 may beconfigured to selectively convey a selected ply carrier 21, togetherwith one or more respective ply segments 92 that may be supported byselected ply carrier 21, from a ply kitting area 100 and/or from a plycarrier staging area 102 thereof to an intermediate location 180. As anexample, intermediate location 180 may include and/or be apredetermined, preselected, and/or selected location 36 along the lengthof elongate forming mandrel 32. As another example, intermediatelocation 180 may include and/or be ply carrier staging area 102 and/oranother ply carrier staging area that is spaced-apart from ply carrierstaging area 102.

Forming machine 50 may be configured to receive selected ply carrier 21from intermediate location 180 and/or from carrier transfer device 40(directly and/or indirectly) and to deform selected ply carrier 21,together with the one or more respective ply segments 92, over aselected portion 38 of elongate ply forming surface 34. During thisdeformation process, the one or more respective ply segments 92 may belocated between selected ply carrier 21 and selected portion 38 ofelongate ply forming surface 34. Subsequently, forming machine 50 mayseparate selected ply carrier 21 from the respective ply segment 92 suchthat respective ply segment 92 is supported by selected portion 38 ofelongate ply forming surface 34. Forming machine 50 then may returnselected ply carrier 21 to carrier transfer device 40, which may returnselected ply carrier 21 to ply carrier staging area 102.

The above-described process may be repeated any suitable number of timesto locate any suitable number of ply segments 92 on elongate ply formingsurface 34. As an example, forming machine 50 may be configured totranslate along the length of elongate forming mandrel 32 and to receiveand deform a plurality of selected ply carriers 21 and respective plysegments 92 and at a plurality of different selected locations 36 alongthe length of elongate forming mandrel 32. This is illustrated in FIG. 3by forming machine 50 translating between a first selected location(with forming machine 50 illustrated in dash-dot lines) and a secondselected location (with forming machine 50 illustrated in solid lines).Additionally or alternatively, the dash-dot lines in FIG. 3 may indicatethat a single elongate forming mandrel 32 may have a plurality offorming machines 50 associated therewith.

This motion of forming machine 50 may permit ply segments 92 to belocated and/or placed end-to-end along a length of elongate ply formingsurface 34 to generate, create, and/or define a given ply 90, or layer90, of uncured composite structure 810. Additionally or alternatively,ply segments 92 may be located and/or placed in an overlapping, stacked,or layered, fashion on elongate ply forming surface 34 to generate,create, and/or define a plurality of different, or layered, plies 90 ofuncured composite structure 810.

As illustrated in dashed lines in FIG. 3, system 18 further may includea plurality of ply kitting tools 60. Ply kitting tools 60 may beadapted, configured, designed, and/or constructed tocreate ply segments92, such as by cutting ply segments 92 from a composite feedstock 88 ofcomposite material. Ply kitting tools 60 may be automated. As such, plykitting tools 60 also may be referred to herein as automated ply kittingtools 60 and/or as numerically controlled ply kitting tools 60. As anexample, ply kitting tools 60 may include and/or be a plurality of plykitting robots 62.

As discussed in more detail herein, ply segments 92 may have and/ordefine a plurality of different configurations. As examples, differentply segments 92 may be shaped to be received on a specific and/orpredetermined portion of elongate ply forming surface 34 and/or may beshaped to define a specific portion of uncured composite structure 810.As such, different ply segments 92 may have and/or define differentshapes, compositions, and/or different fiber orientations and/or may becreated from different composite feedstocks 88.

At a given point in time, each ply kitting tool 60 may be adapted,configured, and/or programmed to create and/or define a respective plysegment 92, such as may have a given, or predetermined, shape,composition, and/or fiber orientation. In addition, each ply kittingtool 60 may be adapted, configured, and/or programmed to operateindependently from a remainder of the ply kitting tools 60. Furthermore,ply kitting tools 60 may be configured to operate, or to createrespective ply segments 92, at least partially concurrently with oneanother. As such, ply segments 92 that are concurrently created and/ordefined by ply kitting tools 60 may have and/or define a plurality ofdifferent configurations, and systems 18 may be configured to track alocation of, or maintain an inventory of, individual ply segments 92, asdiscussed in more detail herein.

As also illustrated in dashed lines in FIG. 3, system 18 further mayinclude a plurality of ply segment locating devices 70. Ply segmentlocating devices 70 may be configured to locate at least one ply segment92 on each ply carrier 20. It is within the scope of the presentdisclosure that a given ply segment locating device 70 may be separateand/or distinct from a corresponding ply kitting tool 60. However, it isalso within the scope of the present disclosure that the given plysegment locating device 70 may form a portion of the corresponding plykitting tool 60. Ply segment locating device 70 may locate and/or placeply segments 92 on ply carriers 20 subsequent to creation of plysegments 92 by ply kitting tools 60. Additionally or alternatively, plysegment locating device 70 may locate and/or place composite feedstock88 on ply carriers 20, with composite feedstock 88 subsequently beingmodified to create one or more ply segments 92 by ply kitting tool 60.

Ply segment locating device 70 may be automated. As such, ply segmentlocating device 70 also may be referred to herein as automated plysegment locating device 70 and/or as numerically controlled ply segmentlocating device 70. As an example, ply segment locating device 70 mayinclude and/or be a ply locating robot 72.

Ply segment locating device 70 may be configured to vacuum compact plysegments 92 onto corresponding ply carriers 20. As such, ply segmentlocating device 70 may include and/or be associated with a segmentvacuum compaction structure 74.

It is within the scope of the present disclosure that a given plysegment locating device 70 may be configured to locate any suitablenumber of ply segments 92 on a given ply carrier 20. As an example, thegiven ply segment locating device may be configured to locate a singleply segment 92 on the given ply carrier 20. As another example, thegiven ply segment locating device may be configured to locate at leasttwo ply segments 92 on the given ply carrier 20.

When the given ply segment locating device 70 locates two or more plysegments 92 on the given ply carrier 20, the two or more ply segments 92may be located in any suitable manner. As an example, the two or moreply segments 92 may be located such that they define a plurality ofstacked ply segments 92. As another example, the two or more plysegments 92 may be located in a spaced-apart manner on the given plycarrier 20. As yet another example, a first fiber orientation of a firstply segment 92 that is supported by the given ply carrier 20 may bedifferent from a second fiber orientation of a second ply segment 92that is supported by the given ply carrier 20.

As further illustrated in dashed lines in FIG. 3, system 18 may includea plurality of ply carrier magazines 28. Each ply carrier magazine 28may be configured to contain, house, enclose, and/or otherwise support arespective plurality of ply carriers 20 and corresponding ply segment(s)92 that may be supported thereby. As examples, each ply carrier magazine20 may be configured to contain at least 2, at least 3, at least 4, atleast 5, at least 6, at least 7, at least 8, or at least 10 ply carriers20.

Ply carrier magazines 28 may support ply carriers 20 in any suitablemanner. As an example, ply carrier magazines 20 may include a pluralityof slots. The plurality of slots may be configured to receive and/orsupport the respective plurality of ply carriers 20 in a spaced-apartmanner.

Ply carrier magazines 28 also may be configured to protect therespective plurality of ply carriers 20 from contamination, from anambient environment, and/or from particulate matter. In addition, plycarrier magazines 28 may be configured to retain the respectiveplurality of ply carriers 20 in a vertical, or at least substantiallyvertical, orientation; however, this is not required, and ply carriermagazines 28 additionally or alternatively may be configured to retainthe respective plurality of ply carriers 20 in a horizontal, or at leastsubstantially horizontal, orientation. While not required, such avertical orientation may decrease a floor space needed by ply carriermagazines 28, thereby increasing a spatial efficiency of systems 18.

As also illustrated in dashed lines in FIG. 3, system 18 may include amagazine transfer device 80. Magazine transfer device 80 may beconfigured to selectively convey ply carrier magazines 28 within plykitting area 100 and/or between a kitting tool area 104 and ply carrierstaging area 102, as discussed in more detail herein. Magazine transferdevice 80 may be automated. As such, magazine transfer device 80 alsomay be referred to herein as automated magazine transfer device 80. Asmore specific examples, magazine transfer device 80 may include and/orbe an automated guided vehicle 82 and/or a magazine transfer robot 84.

As further illustrated in dashed lines in FIG. 3, system 18 may be, butis not required to be, separated into ply kitting area 100 and a plyassembly area 110. Ply kitting area 100 may include, contain, and/orhouse ply carrier magazine(s) 28, ply kitting tool(s) 60, ply segmentlocating device(s) 70, and/or magazine transfer device(s) 80. Plyassembly area 110 may include, contain, and/or house one or moreelongate forming mandrels 32, one or more carrier transfer devices 40,and/or one or more forming machines 50. In addition, carrier transferdevice 40 may be configured to obtain selected ply carrier 21 from plykitting area 100 and/or to transfer selected ply carrier 21 from plykitting area 100 to ply assembly area 110.

It is within the scope of the present disclosure that ply kitting area100 and ply assembly area 110 may be located on the same floor, orlevel, or on different floors, or levels. As an example, ply kittingarea 100 may be elevated above ply assembly area 110. Alternatively, plyassembly area 110 may be elevated above ply kitting area 100. Statedanother way, ply kitting area 100 and ply assembly area 110 may bespaced-apart from one another, at least in a vertical direction.However, ply kitting area 100 may at least partially, or evencompletely, overlap with ply assembly area 110 in a horizontaldirection. Such a configuration may decrease an amount of overall floor,or building, space required to house system 18. However, such aconfiguration is not required in all embodiments. Thus, ply kitting area100 and ply assembly area 110 alternatively may be spaced-apart from oneanother in the horizontal direction but not in the vertical direction.Alternatively, ply kitting area 100 and ply assembly area 110 may be atleast partially overlapping and/or coextensive.

When ply kitting area 100 and ply assembly area 110 are located ondifferent floors, or levels, carrier transfer device 40 may beconfigured to vertically convey selected ply carrier 21 from ply kittingarea 100 to ply assembly area 110. This may include conveying selectedply carrier 21 while selected ply carrier 21 is in a verticalorientation and/or while selected ply carrier 21 is in a horizontalorientation. When the selected ply carrier is conveyed in the verticalorientation, and as illustrated, system 18 may be configured totransition selected ply carrier 21 to a horizontal orientation prior toselected ply carrier 21 being received and/or deformed by formingmachine 50. As such, carrier transfer device 40 further may include apivot structure 42, which may be configured to selectively rotateselected ply carrier 21 from the vertical orientation to a horizontalorientation prior to receipt of selected ply carrier 21 by formingmachine 50.

As also illustrated in FIG. 3, selected ply carrier 21 may support plysegments 92 on two or more sides of the selected ply carrier. Underthese conditions, pivot structure 42 further may be configured toselectively rotate selected ply carrier 21 about a horizontal axisand/or to rotate selected ply carrier 21 such that the two or more sidesthereof may face toward elongate forming mandrel 32 and/or such that plysegments that are supported on the two more sides of selected plycarrier 21 may be deformed against elongate forming mandrel 32.

As discussed, one or more components of system 18 may be automatedand/or numerically controlled. With this in mind, and as illustrated indashed lines in FIG. 3, system 18 further may include, be associatedwith, and/or be in communication with a controller 120. Controller 120may be adapted, configured, and/or programmed to control the operationof at least a portion of system 18. This may include controlling theoperation of system 18 by performing any suitable portion of methods300, which are discussed in more detail herein with reference to FIG.15. As examples, controller 120 may be programmed to control and/orregulate the operation of carrier transfer device 40, forming machine50, ply kitting tool 60, ply segment locating device 70, magazinetransfer device 80, and/or a wash station 140.

As also discussed, ply segments 92 may include, define, and/or have avariety of different configurations. Under these conditions, controller120 may be programmed to select a given ply carrier 20 for transfer tointermediate location 180 and/or to selected location 36 based, at leastin part, on a structure and/or configuration of a ply segment 92 that issupported by given ply carrier 20 and/or based, at least in part, onselected location 36. As an example, controller 120 may select the givenply carrier 20 such that a ply segment 92 with a predetermined,preselected, and/or specified configuration is located at eachrespective location along the length of elongate forming mandrel 32and/or at each respective location within uncured composite structure810.

As also illustrated in dashed lines in FIG. 3, system 18 may include aply carrier tracking system 130. Ply carrier tracking system 130 may beconfigured to automatically, routinely, and/or electronically track alocation of each ply carrier 20 and/or of each ply segment 92 that maybe included in, associated with, utilized by, and/or transferred withsystem 18. In addition, ply carrier tracking system 130 also may beconfigured to track a structure, conformation, and/or configuration ofeach ply segment 92 that is supported by a ply carrier 20.

Ply carrier tracking system 130 may track ply carriers 20 and/or plysegments 92 in any suitable manner. As an example, ply carrier trackingsystem 130 may include a unique identification structure 134 that may beassociated with, attached to, and/or defined by each ply carrier 20.Examples of unique identification structure 134 include any suitable barcode and/or radio frequency identification (RFID) tag.

FIG. 3 illustrates ply carrier tracking system 130 in a partiallyoverlapping relationship with controller 120 to indicate that plycarrier tracking system 130 may be included in and/or may form a portionof controller 120. However, it is also within the scope of the presentdisclosure that ply carrier tracking system 130 may be separate,distinct, and/or spaced apart from controller 120. Under theseconditions, system 18 further may include a communication linkage 132that may extend and/or permit communication between controller 120 andply carrier tracking system 130.

As illustrated in dashed lines in FIG. 3, system 18 also may include anuncured composite transfer device 150. Uncured composite transfer device150 may be configured to selectively remove uncured composite structure810 from elongate ply forming surface 34 of elongate forming mandrel 32.This may include removal of the plurality of ply segments 92, whichdefines uncured composite structure 810, from the elongate ply formingsurface. Examples of uncured composite transfer device 150 are disclosedin U.S. patent application Ser. No. 14/633,979, the complete disclosureof which is hereby incorporated by reference.

As further illustrated in dashed lines in FIG. 3, system 18 may includea cure mandrel 160. Uncured composite transfer device 150 may beconfigured to transfer and/or convey uncured composite structure 810from elongate forming mandrel 32 to cure mandrel 160, such as to permitand/or facilitate curing of uncured composite structure 810 to at leastpartially produce and/or define composite structure 800. However, thisis not required in all embodiments. As an example, system 18 may beconfigured to cure uncured composite structure 810 on elongate formingmandrel 32.

Cure mandrel 160, when present, may be configured to receive uncuredcomposite structure 810 from uncured composite transfer device 150, andit is within the scope of the present disclosure that cure mandrel 160also may be configured to receive one or more additional and/or separateuncured composite structures 810. Under these conditions, a plurality ofseparate uncured composite structures 810 may be utilized to produceand/or define composite structure 800 subsequent to curing of theseparate uncured composite structures on cure mandrel 160.

System 18 also may include a heating device 170. Heating device 170 maybe associated with elongate forming mandrel 32, may be associated withcure mandrel 160, and/or may be configured to heat uncured compositestructure 810 to cure uncured composite structure 810 and producecomposite structure 800. This may include heating uncured compositestructure 810 while uncured composite structure 810 is located on and/orsupported by elongate forming mandrel 32 and/or by cure mandrel 160.

As discussed in more detail herein, systems 18 may be configured tore-use ply carriers 20, such as to locate a first ply segment 92 on agiven ply carrier 20, to deform the given ply carrier 20 and the firstply segment 92 on elongate forming mandrel 32 with forming machine 50,and subsequently to locate a second ply segment 92 on the given plycarrier 20. Under these conditions, it may be desirable to clean and/orwash ply carriers 20 prior to re-use thereof. With this in mind, system18 also may include a wash station 140. Wash station 140 may beconfigured to receive ply carriers 20 subsequent to a respective plysegment 92 being removed therefrom. In addition, wash station 140 may beconfigured to selectively clean ply carriers 20, such as to facilitatesubsequent re-use of ply carriers 20.

Ply carriers 20 then may be returned to ply kitting area 100, to plycarrier staging area 102, to kitting tool area 104, and/or to plysegment locating device 70, such as to permit ply segment locatingdevice 70 to locate another ply segment 92 on the ply carriers 20. It iswithin the scope of the present disclosure that system 18 may notinclude wash station 140 and/or that ply carriers 20 may be returned toply segment locating device 70 without being washed by wash station 140.

Ply carriers 20 may include and/or be any suitable structure that maydefine ply support surface 22 and/or that may support one or more plysegments 92. Ply carriers 20 and/or ply support surface 22 thereof mayinclude and/or be constructed from any suitable structure and/ormaterial. As examples, ply carrier 20 and/or ply support surface thereofmay be constructed from an elastic material, a flexible material, and/ora latex sheet. As an additional example, ply carriers 20 also mayinclude a rigid, or at least substantially rigid, elongate support thatextends along a length of ply carriers 20. Examples of ply carriers 20are disclosed in U.S. Pat. No. 8,551,380 and U.S. Patent ApplicationPublication No. 2014/0190625, the complete disclosures of which arehereby incorporated by reference.

Elongate forming mandrel 32 may include and/or be any suitable structurethat may have and/or define elongate ply forming surface 34 and/or thatmay support ply segments 92 and/or uncured composite structure 810 thatmay be defined thereby. As discussed, a plurality of ply segments 92 maybe spaced-apart along the length of elongate forming mandrel 32 todefine a given ply 90 of uncured composite structure 810. As such, alength of elongate ply forming surface 34 may be greater than a lengthof any one of the plurality of ply segments 92 that may be supportedthereby. As examples, the length of elongate ply forming surface 34 maybe at least 4, at least 6, at least 8, at least 10, at least 15, or atleast 20 times larger than the length of any one, or even a longest, ofthe plurality of ply segments 92. Additionally or alternatively,elongate ply forming surface 34 may have and/or define a length of atleast 5 meters, at least 10 meters, at least 15 meters, at least 20meters, at least 25 meters, at least 30 meters, at least 35 meters, orat least 40 meters.

When ply segments 92 are spaced-apart along the length of elongateforming mandrel 32, adjacent ply segments 92 may abut one another in anysuitable fashion. As an example, the adjacent ply segments 92 may definea butt splice therebetween. As another example, the adjacent plysegments 92 may define an overlap splice therebetween.

Elongate ply forming surface 34 also may have and/or define any suitableshape. As an example, elongate ply forming surface 34 may define anonplanar shape. Under these conditions, elongate ply forming surface 34also may be referred to herein as a nonplanar elongate ply formingsurface 34. As a more specific example, elongate ply forming surface 34may be shaped to define a surface contour of a stringer for an aircraft.This may include any suitable blade stringer, hat stringer, and/or ventstringer for the aircraft and/or for a wing of the aircraft.

Carrier transfer device 40 may include and/or be any suitable structurethat may be adapted and/or configured to selectively convey selected plycarrier 21 from ply carrier staging area 102 to selected location 36along the length of elongate forming mandrel 32, that may be adaptedand/or configured to remove selected ply carrier 21 from ply carriermagazine 28, and/or that may be adapted and/or configured to returnselected ply carrier 21 to ply carrier magazine 28, wash station 140,and/or ply kitting area 100. This is illustrated in FIG. 3 by carriertransfer device 40 being indicated in dash-dot lines at a first locationalong the length of elongate forming mandrel 32 and being indicated insolid lines at selected location 36.

Carrier transfer device 40 may be controlled by controller 120. Underthese conditions, carrier transfer device 40 also may be referred toherein as an automated carrier transfer device 40 and/or as anumerically controlled carrier transfer device 40. Additionally oralternatively, carrier transfer device 40 may include and/or be acarrier transfer robot 44.

As discussed, carrier transfer device 40 may be adapted, configured,designed, constructed, and/or programmed to selectively and sequentiallyconvey a plurality of different selected ply carriers 21. This mayinclude conveying the plurality of different selected ply carriers tointermediate location 180 and/or to a plurality of different selectedlocations 36 along the length of elongate forming mandrel 32. This alsomay include horizontally conveying selected ply carrier 21 along thelength of elongate forming mandrel 32. Forming machine 50 may beconfigured to selectively and sequentially receive the plurality ofselected ply carriers and to deform each of the plurality of selectedply carriers at respective locations along the length of elongateforming mandrel 32, thereby defining plies 90 and/or uncured compositestructure 810.

It is within the scope of the present disclosure that carrier transferdevice 40 may be configured to transition to a staging locationsubsequent to receipt of selected ply carrier 21 by forming machine 50and prior to return of the selected ply carrier from the forming machineto the carrier transfer device. It is also within the scope of thepresent disclosure that carrier transfer device 40 may be configured toreturn selected ply carrier 21 to ply carrier magazine 28 subsequent toreturn of selected ply carrier 21 from forming machine 50 to carriertransfer device 40.

Forming machine 50 may include any suitable structure that may beadapted, configured, designed, constructed, and/or programmed to deformselected ply carrier 21 and respective ply segment 92, to separate theselected ply carrier from the respective ply segment, and/or to returnthe selected ply carrier to carrier transfer device 40. This may includedeforming the selected ply carrier and the respective ply segment with adeformation device 51, which may form a portion of forming machine 50,and/or separating the selected ply carrier from the respective plysegment with a ply release structure 53, which may form a portion offorming machine 50.

Forming machine 50 may be automated. As such, forming machine 50 alsomay be referred to herein as an automated forming machine 50 and/or as anumerically controlled forming machine 50. As an example, formingmachine 50 may include and/or be a forming robot 52.

Forming machine 50 may be configured to deform selected ply carrier 21and respective ply segment 92 in a direction that is transverse to alongitudinal axis of elongate ply forming surface 34. This may includewrapping selected ply carrier 21 and respective ply segment 92 aroundelongate ply forming surface 34.

As discussed, forming machine 50 may be configured to translate alongthe length of elongate forming mandrel 32. To facilitate thistranslation, forming machine 50 may include a forming machinetranslation device 54. Forming machine translation device 54 may includeany suitable structure, such as a motor and/or a linear actuator, thatmay be configured to selectively translate forming machine 50 along thelength of elongate forming mandrel 32.

Forming machine 50 also may include a forming machine compaction device56. Forming machine compaction device 56 may be configured to compactthe respective ply segment 92 on selected portion 38 of elongate plyforming surface 34.

As discussed, forming machine 50 may be configured to receive selectedply carrier 21 from carrier transfer device 40. As such, forming machine50 may include an end effector 58 that may be configured to operativelyreceive, retain, and/or support selected ply carrier 21.

Ply segments 92 may include and/or be any suitable structure and/ormaterial that may at least partially define plies 90, uncured compositestructure 810, and/or composite structure 800. As examples, one or moreply segments 92 may include one or more of a fiberglass, a fiberglasscloth, a carbon fiber, a carbon fiber cloth, a cloth, a pre-impregnated(pre-preg) composite material, a resin material, and/or an epoxy.

FIGS. 4-14 are less schematic representations of composite structurefabrication systems 18 according to the present disclosure. Systems 18of FIGS. 4-14 may include and/or be more detailed representations ofsystems 18 of FIG. 3. As such, any of the structures, functions,components, and/or features of systems 18 that are discussed herein withreference to any one of FIGS. 4-14 may be included in and/or utilizedwith systems 18 of FIG. 3 without departing from the scope of thepresent disclosure. Similarly, any of the structures, functions,components, and/or features of systems 18 of FIG. 3 may be included inand/or utilized with systems 18 of FIGS. 4-14 without departing from thescope of the present disclosure.

FIG. 4 is a less schematic top view of a composite structure fabricationsystem 18 according to the present disclosure, and FIG. 5 is a lessschematic profile view of composite structure fabrication system 18. Asillustrated in FIGS. 4-5, system 18 may include a plurality of elongateforming mandrels 32 and a plurality of associated forming machines 50that may be arranged within a ply assembly area 110.

As discussed herein, forming machines 50 may be configured to moveand/or translate along a length of elongate forming mandrels 32, andthis is illustrated in FIGS. 4-5 by forming machines 50 being located atdiffering locations along the length of respective forming mandrels 32.As also illustrated in FIGS. 4-5, system 18 further may include aplurality of ply kitting tools 60 that may be arranged within a plykitting area 100. Ply kitting area 100 also may include a plurality ofply carrier magazines 28.

FIGS. 6-8 are less schematic views of portions of a ply kitting area 100according to the present disclosure. As illustrated in FIG. 6, a plykitting tool 60 may include a ply kitting robot 62 that may beconfigured to receive a ply carrier 20 that has one or more ply segments92 located thereon. Ply kitting robot 62 also may locate ply carriers 20within a ply carrier magazine 28 for storage and/or staging of plycarriers 20.

As further illustrated in FIG. 6, ply kitting tools 60 also may includeand/or be associated with a ply segment locating device 70, which may beconfigured to operatively located ply segments 92 on respective plycarriers 20. As discussed, ply segment locating device 70 may beseparate and/or distinct from ply kitting tool 60. Alternatively, plysegment locating device 70 may form a portion of ply kitting tool 60and/or ply kitting robot 62.

FIG. 7 illustrates more clearly that a plurality of ply carriermagazines 28 may be located and/or staged within ply kitting area 100,or within a ply carrier staging area 102 thereof. This may permit aselected, given, and/or predetermined ply segment 92 to be conveyed to arespective forming machine 50 on a respective elongate forming mandrel32 (as illustrated in FIGS. 4-5). FIG. 7 also illustrates that plycarrier magazines 28 may include, be operatively attached to, and/or beassociated with respective magazine transfer devices 80.

As illustrated in FIG. 8, ply carrier magazines 28 may be located and/orstaged within ply carrier staging area 102 of ply kitting area 100 suchthat a carrier transfer device 40 may receive and/or remove a selectedply carrier 21 from a given ply carrier magazine 28. Carrier transferdevice 40 then may convey selected ply carrier 21, together withcorresponding ply segments 92, from ply carrier staging area 102 of plykitting area 100 to ply assembly area 110, as illustrated in FIG. 9.This may include conveying selected ply carrier 21 in a verticaldirection and/or maintaining selected ply carrier 21 in a vertical, orupright, orientation 46 (as illustrated in FIG. 10) while it isconveyed.

Subsequently, and as illustrated in FIG. 10, carrier transfer device 40may transition and/or pivot from the vertical, or upright, orientation46 to a horizontal orientation 48. This may include pivoting at least aportion of carrier transfer device 40 about a pivot structure 42thereof. As illustrated in FIG. 11, carrier transfer device 40 then mayconvey selected ply carrier 21 along a length of an associated elongateforming mandrel 32 and to a selected location 36. This may beaccomplished utilizing a carrier transfer robot 44 that may beassociated with and/or may form a portion of carrier transfer device 40.

Forming machine 50 also may move to and/or may be located at selectedlocation 36, and carrier transfer device 40 may transfer selected plycarrier 21 to forming machine 50. This is illustrated in FIG. 12.Forming machine 50 then may deform selected ply carrier 21 and at leastone respective ply segment 92 over a selected portion 38 of an elongateply forming surface 34 that is defined by elongate forming mandrel 32.Subsequently, and as illustrated in FIG. 13, carrier transfer device 40may return selected ply carrier 21 to ply kitting area 100 while the atleast one respective ply segment 92 is retained on selected portion 38.

As discussed herein, this process may be repeated any suitable number oftimes to locate any suitable number of ply segments 92 on elongate plyforming surface 34 such that ply segments 92 generate, create, and/ordefine a plurality of layered plies 90 that define an uncured compositestructure 810. This is illustrated in FIG. 14. As also illustrated inFIG. 14, an uncured composite transfer device 150 then may be utilizedto remove a given uncured composite structure 810 from a given elongateforming mandrel 32 and/or to transfer uncured composite structure 810 toa cure mandrel, as discussed in more detail herein.

FIG. 15 is a flowchart depicting methods 300, according to the presentdisclosure, of fabricating a composite structure. Methods 300 mayinclude creating a plurality of ply segments at 305, locating at leastone ply segment on each ply carrier of a plurality of ply carriers at310, storing the plurality of ply carriers within a ply carrier magazineat 315, transferring a plurality of ply carrier magazines at 320,receiving a selected ply carrier from the ply carrier magazine at 325,and/or electronically tracking each ply carrier at 330. Methods 300include conveying the selected ply carrier at 335, translating a formingmachine at 340, receiving the selected ply carrier at 345, deforming theselected ply carrier at 350, releasing a respective ply segment at 355,and returning the selected ply carrier at 360. Methods 300 further mayinclude cleaning the selected ply carrier at 365 and include repeatingat least a portion of the methods at 370. Methods 300 also may includetransferring an uncured composite structure to a cure mandrel at 375and/or curing the uncured composite structure at 380.

Creating the plurality of ply segments at 305 may include creating with,or utilizing, a plurality of ply kitting tools. The creating at 305further may include creating a respective ply segment of the pluralityof ply segments with each ply kitting tool in the plurality of plykitting tools. This may include independently creating a different plysegment with each ply kitting tool and/or concurrently creating at leasttwo ply segments with at least two different ply kitting tools.

As used herein, the phrase, “creating the plurality of ply segments” orsimply the word “creating,” when utilized in the context of the plysegments, may indicate that the ply segments are created, formed,produced, generated, defined, constructed, built, and/or made in anysuitable manner. As an example, and as discussed, the ply segments maybe created from a feedstock. This may include cutting the feedstock,severing the feedstock, laying up the feedstock, and/or layering thefeedstock.

The creating at 305 may be accomplished in any suitable manner. As anexample, the creating at 305 may include cutting a respective plysegment from a composite feedstock. As a more specific example, thecreating at 305 may include creating a first ply segment with a firstply kitting tool and concurrently creating a second ply segment with asecond ply kitting tool. The first ply segment may be different from thesecond ply segment. As examples, the first ply segment may have adifferent boundary, periphery, and/or peripheral shape than the secondply segment. As another example, the first ply segment may have adifferent fiber orientation than the second ply segment. As yet anotherexample, the first ply segment may be creating from a differentmaterial, such as from a different composite feedstock, than the secondply segment.

Locating at least one ply segment on each ply carrier at 310 may includelocating with a ply segment locating device and/or locating with the plykitting tool, as discussed herein. The locating at 310 may includelocating any suitable number of ply segments on each ply carrier and/orlocating a different ply segment, or a different number of ply segments,on different ply carriers. As an example, the locating at 310 mayinclude locating a single ply segment on at least one ply carrier. Asanother example, the locating at 310 also may include locating aplurality of ply segments on at least one, or a different, ply carrier.This may include locating such that the plurality of ply segmentsdefines a plurality of stacked, or layered, ply segments. Additionallyor alternatively, this also may include locating such that at least aportion of the plurality of ply segments is spaced apart from aremainder of the plurality of ply segments on a respective ply supportsurface of the at least one ply carrier. As yet another example, thelocating at 310 may include locating such that a first fiber orientationof a first ply segment that is located on the respective ply supportsurface is different from a second fiber orientation of a second plysegment that is located on the respective ply support surface. It iswithin the scope of the present disclosure that the locating at 310further may include vacuum compacting the at least one ply segment oneach ply carrier.

Storing the plurality of ply carriers within the ply carrier magazine at315 may include storing a respective subset of the plurality of plycarriers within each ply carrier magazine. This may include storing anysuitable number of ply carriers in each ply carrier magazine and/orstoring a different number of ply carriers in at least one ply carriermagazine when compared to at least one other ply carrier magazine. Asexamples, the storing at 315 may include storing at least 2, at least 3,at least 4, at least 5, at least 6, at least 8, or at least 10 plycarriers in each of the plurality of ply carrier magazines.

It is within the scope of the present disclosure that the ply carriersmay include and/or be elongate ply carriers that may have and/or definean elongate axis. Under these conditions, the storing at 315 may includestoring the respective subset of the plurality of ply carriers in anupright, or at least substantially upright, orientation. This mayinclude vertically storing, or arranging, the respective subset of theplurality of ply carriers within each ply carrier magazine. Such aconfiguration may decrease a floor space requirement of the ply carriermagazines, as discussed herein.

It is also within the scope of the present disclosure that the storingat 315 additionally or alternatively may include protecting therespective subset of the plurality of ply carriers from an ambientenvironment that surrounds the ply carrier magazines. As an example, thestoring at 315 may include restricting contact between the respectivesubset of the plurality of ply carriers and particulate material, suchas by sealing the ply carrier magazines and/or by enclosing therespective subset of the plurality of ply carriers within acorresponding ply carrier magazine.

Transferring the plurality of ply carrier magazines at 320 may includetransferring from a kitting tool area to a ply carrier staging area.This may include transferring with a magazine transfer device, examplesof which are discussed herein.

Receiving the selected ply carrier from the ply carrier magazine at 325may include receiving the selected ply carrier from a respective plycarrier magazine of the plurality of ply carrier magazines and may beperformed prior to the conveying at 335. The receiving at 325 mayinclude receiving with a carrier transfer device, examples of which arediscussed herein.

Electronically tracking each ply carrier at 330 may includeelectronically tracking any suitable parameter and/or characteristic ofeach ply carrier of the plurality of ply carriers. As an example, theelectronically tracking at 330 may include electronically tracking alocation of each ply carrier of the plurality of ply carriers. Asanother example, the electronically tracking at 330 additionally oralternatively may include electronically tracking a structure of atleast one ply segment that is supported by each ply carrier of theplurality of ply carriers. As yet another example, the electronicallytracking at 330 may include uniquely identifying each ply carrier of theplurality of ply carriers, such as via associating and/or utilizing aunique bar code and/or a unique radio frequency identification tag witheach ply carrier. As another example, the electronically tracking at 330may include maintaining a database of information, such as of thetracked parameters and/or of the characteristics, for each ply carrier.

It is within the scope of the present disclosure that the electronicallytracking at 330 may be performed at any suitable time and/or with anysuitable sequence during methods 300. As examples, the electronicallytracking at 330 may be performed prior to, during, and/or subsequent tothe forming at 305, the locating at 310, the storing at 315, thetransferring at 320, the receiving at 325, the conveying at 335, thetranslating at 340, the receiving at 345, the deforming at 350, thereleasing at 355, the returning at 360, the cleaning at 365, and/or therepeating at 370.

Conveying the selected ply carrier at 335 may include conveying theselected ply carrier with the carrier transfer device. This may includeconveying the selected ply carrier from the ply carrier staging area,from a ply kitting area, from the ply kitting area to a ply assemblyarea, and/or to a selected location along a length of an elongateforming mandrel. The elongate forming mandrel may define an elongate plyforming surface that is shaped to define a surface contour of thecomposite structure. In addition, the elongate ply forming surface alsomay be configured to receive the plurality of ply segments such that theplurality of ply segments defines a plurality of plies of compositematerial. The plurality of plies of composite material may at leastpartially produce and/or define the composite structure and/or maydefine the uncured composite structure.

As discussed in more detail herein, the ply carrier magazines may belocated within a ply kitting area and/or within a ply carrier stagingarea of the ply kitting area. As also discussed in more detail herein,the elongate forming mandrel may be located in a ply assembly area thatis different from, spaced-apart from, and/or at a different elevationthan the ply kitting area. As an example, the ply kitting area may bespaced apart from the ply assembly area in a vertical direction, such aswhen the ply kitting area is elevated above the ply assembly area orwhen the ply assembly area is elevated above the ply kitting area. Inaddition, the ply kitting area may be at least partially overlappingwith the ply assembly area in a horizontal direction.

Under these conditions, the conveying at 335 may include verticallyconveying the selected ply carrier from the ply kitting area to the plyassembly area. This may include conveying the selected ply carrier whilethe selected ply carrier is in the vertical orientation and/or in thehorizontal orientation, as discussed herein. This also may includerotating the selected ply carrier to a horizontal orientation prior toconveying the selected ply carrier along the length of the elongateforming mandrel and/or prior to the receiving at 345. In addition, theconveying at 335 also may include horizontally conveying the selectedply carrier along the length of the elongate forming mandrel.

Translating the forming machine at 340 may include translating theforming machine along the length of the elongate forming mandrel and/ortranslating the forming machine to the selected location. Thetranslating at 340 may be performed at any suitable time and/or with anysuitable sequence during methods 300. As examples, the translating at340 may be at least partially concurrent with the conveying at 335, withthe electronically tracking at 330, with the receiving at 325, with thetransferring at 320, with the storing at 315, with the locating at 310,and/or with the creating at 305.

Receiving the selected ply carrier at 345 may include receiving theselected ply carrier from the carrier transfer device and/or receivingthe selected ply carrier with the forming machine. This may includesupporting the selected ply carrier with the forming machine and/or withan end effector of the forming machine.

Deforming the selected ply carrier at 350 may include deforming theselected ply carrier and a respective ply segment, which is supported bythe selected ply carrier, with the forming machine. This may includedeforming over a selected portion of the elongate ply forming surface.The deforming at 350 may include deforming the selected ply carrier andthe respective ply segment in a direction that is transverse to a long,or longitudinal, axis of the ply forming surface. Additionally oralternatively, the deforming at 350 may include locating the respectiveply segment between the elongate ply forming surface and the selectedply carrier during the deforming. It is within the scope of the presentdisclosure that the deforming at 350 further may include compacting therespective ply segment on the elongate ply forming surface. Thecompacting may be performed during the deforming at 350, as part of thedeforming at 350, subsequent to the deforming at 350, and/or subsequentto the releasing at 355. The compacting may be accomplished in anysuitable manner, such as utilizing a compaction device that may form aportion of and/or may be associated with the forming machine.

The deforming at 350 may be performed at any suitable time and/or withany suitable sequence during methods 300. As examples, the deforming at350 may be subsequent to the receiving at 345, to the translating at340, and/or to the conveying at 335. Additionally or alternatively, thedeforming at 350 also may be at least partially concurrent with theelectronically tracking at 330, with the receiving at 325, with thetransferring at 320, with the storing at 315, with the locating at 310,and/or with the creating at 305.

Releasing the respective ply segment at 355 may include releasing therespective ply segment from the selected ply carrier while retaining therespective ply segment on, in contact with, and/or adhered to theselected portion of the elongate ply forming surface. This may includeoperatively separating the respective ply segment from the selected plycarrier and/or translating the selected ply carrier away from therespective ply segment.

Returning the selected ply carrier at 360 may include returning theselected ply carrier to the ply kitting area and/or to the carriertransfer device and may be performed subsequent to the deforming at 350and/or subsequent to the releasing at 355. This may include transferringthe selected ply carrier from the forming machine to the carriertransfer device and/or supporting the selected ply carrier with thecarrier transfer device. The returning at 360 further may includereturning the selected ply carrier to the respective ply carriermagazine.

Cleaning the selected ply carrier at 365 may include cleaning to permitand/or facilitate locating another ply segment on the selected plycarrier. As an example, the selected ply carrier may be re-used aplurality of times during methods 300, such as during the repeating at370. Under these conditions, it may be desirable to clean and/orcondition the ply support surface of the selected ply carrier, such asto decrease a potential for contamination of a ply segment that issupported thereby and/or to increase adhesion between the ply segmentand the ply support surface.

The cleaning at 365 may be accomplished in any suitable manner. As anexample, the cleaning at 365 may include cleaning with, or by sendingthe selected ply carrier through, a wash station. It is within the scopeof the present disclosure that the cleaning at 365 may be performed atany suitable time, with any suitable sequence, and/or with any suitablefrequency during methods 300. As examples, the cleaning at 365 may beperformed prior to the locating at 310, prior to each instance of thelocating at 310, subsequent to the releasing at 355, subsequent to eachinstance of the releasing at 355, subsequent to a preselected number ofinstances of the locating at 310 and/or of the releasing at 355, and/orresponsive to detection of greater than a threshold level ofcontaminants on the ply support surface of the selected ply carrier.

Repeating at least the portion of the methods at 370 may includerepeating any suitable portion of methods 300 with any suitablefrequency and/or in any suitable order. As an example, the repeating at370 may include repeating at least the conveying at 335, the translatingat 340, the receiving at 345, the deforming at 350, the releasing at355, and the returning at 360 with all or a portion of the plurality ofply carriers. Each of the plurality of ply carriers may support arespective ply segment, and the repeating may include repeating tolocate the plurality of ply segments on the elongate ply formingsurface, thereby at least partially producing the uncured compositestructure.

The repeating at 370 further may include selecting a location within theuncured composite structure for each ply segment and/or selecting acomposition of each ply segment. As discussed, a location and/orcomposition of each ply segment may be electronically tracked, such asvia the tracking at 330, and the location of each ply segment may beselected based, at least in part, on the shape and/or composition of theply segment. Stated another way, a specific ply segment may be created,such as during the creating at 305, for each location of a plurality oflocations within the uncured composite structure, and the repeating at370 may include selectively locating each ply segment at a correspondingand/or predetermined location within the uncured composite structure.

The repeating at 370 additionally or alternatively may includeincrementally translating the forming machine along the length of theforming mandrel. This may include incrementally translating the formingmachine a first time to locate a first course, layer, or ply ofcomposite material on the elongate ply forming surface and subsequentlyincrementally translating the forming machine along the length of theforming mandrel a second time to locate a second course, layer, or plyof composite material on the first course of composite material. Thefirst course of composite material may include a first subset of theplurality of ply segments and the second course of composite materialmay include a second, or different, subset of the plurality of plysegments. This process may be repeated any suitable number of times tolocate and/or build up any suitable number of plies of compositematerial on the elongate ply forming surface. Stated another way, therepeating at 370 may include repeating to retain the plurality of plysegments on a plurality of different selected portions of the elongateply forming surface.

Transferring the uncured composite structure to the cure mandrel at 375may include transferring from the elongate ply forming surface of theelongate forming mandrel to the cure mandrel. The transferring at 375may be accomplished in any suitable manner. As an example, thetransferring at 375 may include transferring with an uncured compositetransfer device, examples of which are disclosed herein. It is withinthe scope of the present disclosure that the transferring at 375 mayinclude transferring a single uncured composite structure to the curemandrel. Alternatively, it is also within the scope of the presentdisclosure that, prior to the curing at 380, the transferring at 375 maybe repeated to transfer at least one other uncured composite structure,or a plurality of uncured composite structures, to the cure mandrel. Theplurality of uncured composite structures then may be cured, such as viathe curing at 380, to together, or collectively, define the compositestructure.

Curing the uncured composite structure at 380 may include heating theuncured composite structure to cure the uncured composite structure andproduce a cured composite structure (i.e., the composite structure).This may include heating with any suitable heating device, examples ofwhich are disclosed herein. When methods 300 include the transferring at375, the curing at 380 may include curing on the cure mandrel.Alternatively, and when methods 300 do not include the transferring at375, the curing at 380 may include curing on the elongate formingmandrel.

Referring now to FIGS. 16-17, embodiments of the disclosure may bedescribed in the context of an aircraft manufacturing and service method900, as shown in FIG. 16, and/or an aircraft 700, as shown in FIG. 17.During pre-production, exemplary method 900 may include specificationand design 905 of the aircraft 700 and material procurement 910. Duringproduction, component and subassembly manufacturing 915 and systemintegration 920 of the aircraft 700 take place. Thereafter, the aircraft700 may go through certification and delivery 925 in order to be placedin service 930. While in service by a customer, the aircraft 700 isscheduled for routine maintenance and service 935 (which also mayinclude modification, reconfiguration, refurbishment, and so on).

Each of the processes of method 900 may be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator may includewithout limitation any number of aircraft manufacturers and major-systemsubcontractors; a third party may include without limitation any numberof venders, subcontractors, and suppliers; and an operator may be anairline, leasing company, military entity, service organization, and soon.

As shown in FIG. 17, aircraft 700 produced by exemplary method 900 mayinclude an airframe 710 with a plurality of systems 712 and an interior714. Examples of high-level systems 712 include one or more of apropulsion system 715, an electrical system 716, a hydraulic system 717,and an environmental system 718. Any number of other systems may beincluded. Although an aerospace example is shown, the principles of theinvention may be applied to other industries, such as the automotiveindustry.

Systems and methods embodied herein may be employed during any one ormore of the stages of the manufacturing and service method 900. Forexample, components or subassemblies corresponding to component andsubassembly manufacturing process 915 may be fabricated or manufacturedin a manner similar to components or subassemblies produced while theaircraft 700 is in service. Also, one or more of system embodiments,method embodiments, or a combination thereof may be utilized during theproduction stages 915 and 920, for example, by substantially expeditingassembly of or reducing the cost of an aircraft 700. Similarly, one ormore of system embodiments, method embodiments, or a combination thereofmay be utilized while the aircraft 700 is in service, for example andwithout limitation, to maintenance and service 935.

Examples of inventive subject matter according to the present disclosureare described in the following enumerated paragraphs:

A1. A composite structure fabrication system, comprising:

a plurality of ply carriers, wherein each of the plurality of plycarriers defines a ply support surface configured to temporarily supportat least one ply segment;

an elongate forming mandrel that defines an elongate ply formingsurface, wherein the elongate ply forming surface is shaped to define asurface contour of the composite structure and is configured to receivea plurality of ply segments to define a plurality of plies of compositematerial that at least partially defines the composite structure;

a carrier transfer device configured to selectively convey a selectedply carrier of the plurality of ply carriers from a ply kitting area toan intermediate location, optionally wherein the carrier transfer deviceis configured to selectively convey the selected ply carrier from a plycarrier staging area of the ply kitting area, and further optionallywherein the intermediate location includes a selected location along alength of the elongate forming mandrel; and

a forming machine configured to receive the selected ply carrier at theintermediate location and to deform the selected ply carrier and arespective ply segment over a selected portion of the elongate plyforming surface, separate the selected ply carrier from the respectiveply segment such that the respective ply segment is supported by theselected portion of the elongate ply forming surface, and return theselected ply carrier to the carrier transfer device.

A2. The system of paragraph A1, wherein the system further includes aplurality of ply kitting tools configured to create the plurality of plysegments.

A3. The system of paragraph A2, wherein the plurality of ply kittingtools includes a plurality of automated ply kitting tools.

A4. The system of any of paragraphs A2-A3, wherein the plurality of plykitting tools includes a plurality of numerically controlled ply kittingtools.

A5. The system of any of kitting tool area paragraphs A2-A4, wherein theplurality of ply kitting tools includes a plurality of ply kittingrobots.

A6. The system of any of paragraphs A2-A5, wherein each of the pluralityof ply kitting tools is configured to create a respective ply segment ofthe plurality of ply segments.

A7. The system of any of paragraphs A2-A6, wherein each of the pluralityof ply kitting tools is configured to operate independently from aremainder of the plurality of ply kitting tools.

A8. The system of any of paragraphs A2-A7, wherein each of the pluralityof ply kitting tools is configured to operate at least partiallyconcurrently with at least one other of the plurality of ply kittingtools.

A9. The system of any of paragraphs A2-A8, wherein each of the pluralityof ply kitting tools is configured to cut a/the respective ply segmentof the plurality of ply segments from a composite feedstock.

A10. The system of any of paragraphs A2-A9, wherein a first ply kittingtool of the plurality of ply kitting tools is configured to create afirst ply segment and a second ply kitting tool of the plurality of plykitting tools is configured to create a second ply segment.

All. The system of paragraph A10, wherein the first ply segment isdifferent from the second ply segment.

A12. The system of any of paragraphs A10-A11, wherein the first plysegment has a different shape than the second ply segment.

A13. The system of any of paragraphs A10-A12, wherein the first plysegment has a different fiber orientation than the second ply segment.

A14. The system of any of paragraphs A10-A13, wherein the first plysegment is created from a different composite feedstock than the secondply segment.

A15. The system of any of paragraphs A1-A14, wherein the system furtherincludes a ply segment locating device configured to locate the at leastone ply segment on each of the plurality of ply carriers.

A16. The system of paragraph A15, wherein the ply segment locatingdevice forms a portion of a/the ply kitting tool.

A17. The system of any of paragraphs A15-A16, wherein the ply segmentlocating device includes an automated ply segment locating device.

A18. The system of any of paragraphs A15-A17, wherein the ply segmentlocating device includes a numerically controlled ply segment locatingdevice.

A19. The system of any of paragraphs A15-A18, wherein the ply segmentlocating device includes a ply locating robot.

A20. The system of any of paragraphs A15-A19, wherein the ply segmentlocating device is configured to vacuum compact the at least one plysegment on each of the plurality of ply carriers.

A21. The system of any of paragraphs A15-A20, wherein the systemincludes a plurality of ply locating assemblies configured to locate theat least one ply segment on a respective subset of the plurality of plycarriers.

A22. The system of paragraph A21, wherein each of the plurality of plylocating assemblies is associated with a respective one of a/theplurality of ply kitting tools.

A23. The system of any of paragraphs A15-A22, wherein the ply segmentlocating device is configured to locate a single ply segment on at leastone of the plurality of ply carriers.

A24. The system of any of paragraphs A15-A23, wherein the ply segmentlocating device is configured to locate at least two ply segments on atleast one of the plurality of ply carriers.

A25. The system of paragraph A24, wherein the at least two ply segmentsdefines a plurality of stacked ply segments on a respective ply supportsurface of the at least one of the plurality of ply carriers.

A26. The system of any of paragraphs A24-A25, wherein at least a portionof the at least two ply segments is spaced apart from a remainder of theat least two ply segments on a/the respective ply support surface of theat least one of the plurality of ply carriers.

A27. The system of any of paragraphs A24-A26, wherein a first fiberorientation of a first ply of the at least two ply segments is differentfrom a second fiber orientation of a second ply of the at least two plysegments.

A28. The system of any of paragraphs A1-A27, wherein the system furtherincludes a plurality of ply carrier magazines, wherein each of theplurality of ply carrier magazines is configured to contain a respectivesubset of the plurality of ply carriers.

A29. The system of paragraph A28, wherein each of the plurality of plycarrier magazines is configured to contain at least 2, at least 3, atleast 4, at least 5, at least 6, at least 8, or at least 10 plycarriers.

A30. The system of any of paragraphs A28-A29, wherein each of theplurality of ply carrier magazines includes a plurality of slotsconfigured to receive the respective subset of the plurality of plycarriers in a spaced-apart manner.

A31. The system of any of paragraphs A28-A30, wherein each of theplurality of ply carrier magazines is configured to protect therespective subset of the plurality of ply carriers from particulatematerial.

A32. The system of any of paragraphs A28-A31, wherein each of theplurality of ply carrier magazines is configured to retain therespective subset of the plurality of ply carriers in an at least one ofan at least substantially vertical orientation and an at leastsubstantially horizontal orientation.

A33. The system of any of paragraphs A1-A32, wherein the system furtherincludes a magazine transfer device configured to selectively conveya/the plurality of ply carrier magazines from a kitting tool area to aply carrier staging area.

A34. The system of paragraph A33, wherein the magazine transfer deviceincludes an automated magazine transfer device that optionally isconfigured to selectively convey the plurality of ply carrier magazineswithin the ply kitting area and from a kitting tool area to a plycarrier staging area.

A35. The system of any of paragraphs A33-A34, wherein the magazinetransfer device includes a numerically controlled magazine transferdevice.

A36. The system of any of paragraphs A33-A35, wherein the magazinetransfer device includes an automated guided vehicle.

A37. The system of any of paragraphs A33-A36, wherein the magazinetransfer device includes a magazine transfer robot.

A38. The system of any of paragraphs A1-A37, wherein the carriertransfer device is an automated carrier transfer device.

A39. The system of any of paragraphs A1-A38, wherein the carriertransfer device is a numerically controlled carrier transfer device.

A40. The system of any of paragraphs A1-A39, wherein the carriertransfer device includes a carrier transfer robot.

A41. The system of any of paragraphs A1-A40, wherein the carriertransfer device is configured to remove the selected ply carrier froma/the ply carrier magazine.

A42. The system of paragraph A41, wherein the ply carrier magazine islocated in a ply kitting area and the elongate forming mandrel islocated in a ply assembly area.

A43. The system of paragraph A42, wherein the ply kitting area iselevated above the ply assembly area.

A44. The system of paragraph A42, wherein the ply assembly area iselevated above the ply kitting area.

A45. The system of any of paragraphs A42-A44, wherein the ply kittingarea is spaced apart from the ply assembly area in a vertical direction.

A46. The system of paragraph A45, wherein the ply kitting area is atleast partially overlapping with the ply assembly area in a horizontaldirection.

A47. The system of any of paragraphs A42-A46, wherein the carriertransfer device is configured to convey, and optionally verticallyconvey, the selected ply carrier from the ply kitting area to the plyassembly area.

A48. The system of paragraph A47, wherein the carrier transfer device isconfigured to convey, and optionally vertically convey, the selected plycarrier while the selected ply carrier is in at least one of a verticalorientation and a horizontal orientation.

A49. The system of any of paragraphs A47-A48, wherein the carriertransfer device includes a pivot structure configured to selectivelyrotate the selected ply carrier to a horizontal orientation prior toreceipt of the selected ply carrier by the forming machine.

A50. The system of any of paragraphs A42-A49, wherein the systemincludes the ply kitting area.

A51. The system of paragraph A50, wherein a/the ply kitting tool islocated in the ply kitting area.

A52. The system of any of paragraphs A50-A51, wherein a/the ply segmentlocating device is located in the ply kitting area.

A53. The system of any of paragraphs A50-A52, wherein a/the magazinetransfer device is located in the ply kitting area.

A54. The system of any of paragraphs A42-A53, wherein the systemincludes the ply assembly area.

A55. The system of paragraph A54, wherein the elongate forming mandrelis located in the ply assembly area.

A56. The system of any of paragraphs A54-A55, wherein the carriertransfer device is located in the ply assembly area.

A57. The system of any of paragraphs A54-A56, wherein the formingmachine is located in the ply assembly area.

A58. The system of any of paragraphs A1-A57, wherein the carriertransfer device is configured to selectively and sequentially convey aplurality of selected ply carriers of the plurality of ply carriers tothe intermediate location, and further wherein the forming machine isconfigured to selectively and sequentially receive each of the pluralityof selected ply carriers and to deform each of the plurality of selectedply carriers at respective locations along a length of the elongateforming mandrel.

A59. The system of any of paragraphs A1-A58, wherein the carriertransfer device is configured to horizontally convey the selected plycarrier along the length of the elongate forming mandrel.

A60. The system of any of paragraphs A1-A59, wherein the carriertransfer device is configured to transition to a staging locationsubsequent to receipt of the selected ply carrier by the forming machineand prior to return of the selected ply carrier from the forming machineto the carrier transfer device.

A61. The system of any of paragraphs A1-A60, wherein, subsequent toreturn of the selected ply carrier from the forming machine to thecarrier transfer device, the carrier transfer device is configured toreturn the selected ply carrier to the ply carrier magazine.

A62. The system of any of paragraphs A1-A61, wherein the forming machineis an automated forming machine.

A63. The system of any of paragraphs A1-A62, wherein the forming machineis a numerically controlled forming machine.

A64. The system of any of paragraphs A1-A63, wherein the forming machineis a forming robot.

A65. The system of any of paragraphs A1-A64, wherein the forming machineis configured to deform the selected ply carrier and the respective plysegment in a direction that is transverse to a longitudinal axis of theelongate ply forming surface.

A66. The system of any of paragraphs A1-A65, wherein the forming machineincludes a forming machine translation device configured to selectivelytranslate the forming machine along the length of the elongate formingmandrel.

A67. The system of any of paragraphs A1-A66, wherein the forming machineincludes a compaction device configured to compact the respective plysegment on the selected portion of the elongate ply forming surface.

A68. The system of any of paragraphs A1-A67, wherein the forming machineincludes an end effector configured to receive the selected ply carrierfrom the carrier transfer device.

A69. The system of any of paragraphs A1-A68, wherein the forming machineincludes a deformation device configured to selectively deform theselected ply carrier and the respective ply segment over the selectedportion of the elongate ply forming surface.

A70. The system of any of paragraphs A1-A69, wherein the forming machineincludes a ply release structure configured to selectively separate therespective ply segment from the respective ply support surface.

A71. The system of any of paragraphs A1-A70, wherein a length of theelongate ply forming surface is greater than a length of the respectiveply segment.

A72. The system of paragraph A71, wherein the length of the elongate plyforming surface is at least 4, at least 6, at least 8, at least 10, atleast 15, or at least 20 times larger than the length of the respectiveply segment.

A73. The system of any of paragraphs A1-A72, wherein a/the length of theelongate ply forming surface is greater than a length of any of theplurality of ply segments.

A74. The system of paragraph A73, wherein the length of the elongate plyforming surface is at least 4, at least 6, at least 8, at least 10, atleast 15, or at least 20 times larger than the length of any of theplurality of ply segments.

A75. The system of any of paragraphs A1-A74, wherein at least a portionof the plurality of ply segments is spaced-apart along a/the length ofthe elongate ply forming surface to define a respective ply of theplurality of plies of composite material.

A76. The system of paragraph A75, wherein at least one ply segment ofthe portion of the plurality of ply segments defines a butt splice withat least one other ply segment of the portion of the plurality of plysegments.

A77. The system of any of paragraphs A75-A76, wherein at least one plysegment of the portion of the plurality of ply segments defines anoverlap splice with at least one other ply segment of the portion of theplurality of ply segments.

A78. The system of any of paragraphs A1-A77, wherein at least a portionof the plurality of ply segments defines a layered stack of plysegments.

A79. The system of any of paragraphs A1-A78, wherein the elongate plyforming surface is a nonplanar elongate ply forming surface.

A80. The system of any of paragraphs A1-A79, wherein the elongate plyforming surface is shaped to define a surface contour of a stringer foran aircraft, optionally wherein the stringer includes at least one of ablade stringer, a hat stringer, and a vent stringer.

A81. The system of any of paragraphs A1-A80, wherein a/the length of theelongate ply forming surface is at least 5 meters, at least 10 meters,at least 15 meters, at least 20 meters, at least 25 meters, at least 30meters, at least 35 meters, or at least 40 meters.

A82. The system of any of paragraphs A1-A81, wherein the system furtherincludes a controller programmed to control operation of at least aportion of the system.

A83. The system of paragraph A82, wherein the controller is programmedto perform the method of any of paragraphs B1-B62.

A84. The system of any of paragraphs A82-A83, wherein the controller isprogrammed to control the operation of at least one of:

(i) the carrier transfer device;

(ii) the forming machine;

(iii) a/the ply kitting tool;

(iv) a/the ply segment locating device;

(v) a/the magazine transfer device; and

(vi) a wash station.

A85. The system of any of paragraphs A82-A84, wherein the controller isprogrammed to select a given ply carrier of the plurality of plycarriers for transfer to the intermediate location based, at least inpart, on a structure of the at least one ply segment that is supportedby the given ply carrier.

A86. The system of any of paragraphs A1-A85, wherein the system furtherincludes a ply carrier tracking system.

A87. The system of paragraph A86, wherein the ply carrier trackingsystem is configured to electronically track a location of each plycarrier of the plurality of ply carriers.

A88. The system of any of paragraphs A86-A87, wherein the ply carriertracking system is configured to electronically track a configuration ofthe at least one ply segment that is supported by each ply carrier ofthe plurality of ply carriers.

A89. The system of any of paragraphs A86-A88, wherein the ply carriertracking system forms a portion of a/the controller.

A90. The system of any of paragraphs A86-A89, wherein the ply carriertracking system includes a unique identification structure that isassociated with each ply carrier of the plurality of ply carriers.

A91. The system of paragraph A90, wherein the unique identificationstructure includes at least one of a bar code and a radio frequencyidentification (RFID) tag.

A92. The system of any of paragraphs A1-A91, wherein each of theplurality of ply carriers is configured to be re-used.

A93. The system of any of paragraphs A1-A92, wherein each of theplurality of ply carriers is configured to sequentially support aplurality of different ply segments.

A94. The system of any of paragraphs A1-A93, wherein each of theplurality of ply carriers is configured to be cleaned.

A95. The system of any of paragraphs A1-A94, wherein each of theplurality of ply carriers includes at least one of an elastic material,a flexible material, and a latex sheet, which defines the ply supportsurface.

A96. The system of any of paragraphs A1-A95, wherein each of theplurality of ply carriers includes a rigid elongate support that extendsalong a length thereof.

A97. The system of any of paragraphs A1-A96, wherein the system furtherincludes an uncured composite transfer device configured to selectivelyremove an uncured composite structure, which includes the plurality ofply segments, from the elongate ply forming surface of the elongateforming mandrel.

A98. The system of any of paragraphs A1-A97, wherein the system furtherincludes a cure mandrel configured to receive an/the uncured compositestructure subsequent to the uncured composite structure being defined onthe elongate ply forming surface of the elongate forming mandrel.

A99. The system of paragraph A98, wherein the cure mandrel is configuredto receive a plurality of separate uncured composite structures.

A100. The system of any of paragraphs A1-A99, wherein the system furtherincludes a heating device configured to heat an/the uncured compositestructure to cure the uncured composite structure and produce acomposite structure.

A101. The system of any of paragraphs A1-A100, wherein the systemfurther includes a/the wash station configured to selectively clean agiven ply carrier of the plurality of ply carriers.

A102. The system of any of paragraphs A1-A101, wherein the respectiveply segment is supported by the ply support surface of the selected plycarrier.

A103. The system of any of paragraphs A1-A102, wherein the selected plycarrier is supported by the carrier transfer device and being conveyedto the selected location along the length of the elongate formingmandrel.

A104. The system of any of paragraphs A1-A103, wherein the selected plycarrier has been received by the forming machine.

A105. The system of any of paragraphs A1-A104, wherein the selected plycarrier and the respective ply segment are being deformed over theselected portion of the elongate ply forming surface.

A106. The system of paragraph A105, wherein the respective ply segmentis located between the selected portion of the elongate ply formingsurface and the selected ply carrier.

A107. The system of any of paragraphs A1-A106, wherein the systemfurther includes the respective ply segment.

A108. The system of paragraph A107, wherein the respective ply segmentis released from the selected ply carrier and supported by the selectedportion of the elongate ply forming surface, and further wherein theselected ply carrier is supported by the carrier transfer device.

A109. The system of any of paragraphs A1-A108, wherein the plurality ofply segments includes at least one of a fiberglass, a fiberglass cloth,a carbon fiber, a carbon fiber cloth, a cloth, a pre-impregnated(pre-preg) composite material, a resin material, and/or an epoxy.

B1. A method of fabricating a composite structure, the methodcomprising:

conveying, optionally with at least one of a carrier transfer device anda forming machine, a selected ply carrier from a ply kitting area to aselected location along a length of an elongate forming mandrel thatdefines an elongate ply forming surface, wherein the elongate plyforming surface is shaped to define a surface contour of the compositestructure and is configured to receive a plurality of ply segments todefine a plurality of plies of composite material that at leastpartially defines the composite structure;

translating the forming machine along the length of the elongate formingmandrel to the selected location;

receiving the selected ply carrier, optionally from the carrier transferdevice, with the forming machine;

deforming, with the forming machine, the selected ply carrier and arespective ply segment, which is supported by the selected ply carrier,over a selected portion of the elongate ply forming surface;

releasing the respective ply segment from the selected ply carrier whileretaining the respective ply segment on the selected portion of theelongate ply forming surface;

returning, with the forming machine, the selected ply carrier to atleast one of the ply kitting area and the carrier transfer device; and

repeating the conveying, the translating, the receiving, the deforming,the releasing, and the returning with a plurality of ply carriers, whicheach supports a respective ply segment, to locate the plurality of plysegments on the elongate ply forming surface and at least partiallydefine an uncured composite structure.

B2. The method of paragraph B1, wherein the method further includescreating the plurality of ply segments.

B3. The method of paragraph B2, wherein the creating includes creatingthe plurality of ply segments with a plurality of ply kitting tools.

B4. The method of paragraph B3, wherein the creating includes creating arespective ply segment of the plurality of ply segments with each plykitting tool of the plurality of ply kitting tools.

B5. The method of any of paragraphs B3-B4, wherein the creating includesindependently creating a different ply segment of the plurality of plysegments with each ply kitting tool of the plurality of ply kittingtools.

B6. The method of any of paragraphs B3-B5, wherein the creating includesconcurrently creating at least two ply segments of the plurality of plysegments with two different ply kitting tools of the plurality of plykitting tools.

B7. The method of any of paragraphs B3-B6, wherein the creating includescutting a respective ply of the plurality of ply segments from acomposite feedstock.

B8. The method of any of paragraphs B3-B7, wherein the creating includescreating a first ply segment with a first ply kitting tool andconcurrently creating a second ply segment with a second ply kittingtool.

B9. The method of paragraph B8, wherein the first ply segment has adifferent ply boundary than the second ply segment.

B10. The method of any of paragraphs B8-B9, wherein the first plysegment has a different fiber orientation than the second ply segment.

B11. The method of any of paragraphs B8-B10, wherein the first plysegment is created from a different composite feedstock than the secondply segment.

B12. The method of any of paragraphs B1-B11, wherein the method furtherincludes locating at least one ply segment on each ply carrier of theplurality of ply carriers.

B13. The method of paragraph B12, wherein the locating includes locatingwith a ply segment locating device.

B14. The method of any of paragraphs B12-B13, wherein the locatingfurther includes vacuum compacting the at least one ply segment on eachply carrier of the plurality of ply carriers.

B15. The method of any of paragraphs B12-B14, wherein the locatingincludes locating a single ply segment on at least one of the pluralityof ply carriers.

B16. The method of any of paragraphs B12-B15, wherein the locatingincludes locating at least two ply segments on at least one of theplurality of ply carriers.

B17. The method of paragraph B16, wherein the locating includes locatingsuch that the at least two ply segments defines a plurality of stackedply segments.

B18. The method of any of paragraphs B16-B17, wherein the locatingincludes locating such that at least a portion of the at least two plysegments is spaced apart from a remainder of the at least two plysegments on a respective ply support surface of the at least one of theplurality of ply carriers.

B19. The method of any of paragraphs B16-B18, wherein the locatingincludes locating such that a first fiber orientation of a first plysegment of the at least two ply segments is different from a secondfiber orientation of a second ply segment of the at least two plysegments.

B20. The method of any of paragraphs B1-B19, wherein the method furtherincludes storing a respective subset of the plurality of ply carrierswithin each of a plurality of ply carrier magazines.

B21. The method of paragraph B20, wherein the storing includes storingat least 2, at least 3, at least 4, at least 5, at least 6, at least 8,or at least 10 ply carriers in each of the plurality of ply carriermagazines.

B22. The method of any of paragraphs B20-B21, wherein the storingincludes vertically storing the respective subset of the plurality ofply carriers within each of the plurality of ply carrier magazines.

B23. The method of any of paragraphs B20-B22, wherein the storingincludes restricting contact between the respective subset of theplurality of ply carriers and particulate material with each of theplurality of ply carrier magazines.

B24. The method of any of paragraphs B1-B23, wherein the method furtherincludes transferring a/the plurality of ply carrier magazines from akitting tool area to a ply carrier staging area.

B25. The method of paragraph B24, wherein the transferring includestransferring with a magazine transfer device.

B26. The method of any of paragraphs B1-B25, wherein, prior to theconveying, the method further includes receiving the selected plycarrier from a respective ply carrier magazine of a/the plurality of plycarrier magazines.

B27. The method of paragraph B26, wherein the plurality of ply carriermagazines is located in a ply kitting area and the elongate formingmandrel is located in a ply assembly area.

B28. The method of paragraph B27, wherein the ply kitting area iselevated above the ply assembly area.

B29. The method of any of paragraphs B27-B28, wherein the ply assemblyarea is elevated above the ply kitting area.

B30. The method of any of paragraphs B27-B29, wherein the ply kittingarea is spaced apart from the ply assembly area in a vertical direction.

B31. The method of paragraph B30, wherein the ply kitting area is atleast partially overlapping with the ply assembly area in a horizontaldirection.

B32. The method of any of paragraphs B27-B31, wherein the conveyingincludes vertically conveying the selected ply carrier from the plykitting area to the ply assembly area.

B33. The method of any of paragraphs B27-B32, wherein the conveyingincludes conveying the selected ply carrier while the selected plycarrier is in at least one of a vertical orientation and a horizontalorientation.

B34. The method of any of paragraphs B27-B33, wherein the conveyingfurther includes rotating the selected ply carrier to a horizontalorientation prior to the receiving the selected ply carrier from the plycarrier magazine.

B35. The method of any of paragraphs B1-B34, wherein the method furtherincludes transferring the uncured composite structure from the elongateply forming surface of the elongate forming mandrel to a cure mandrel.

B36. The method of paragraph B35, wherein the method further includestransferring at least one additional uncured composite structure to thecure mandrel.

B37. The method of any of paragraphs B35-B36, wherein the transferringthe uncured composite structure includes transferring with an uncuredcomposite transfer device.

B38. The method of any of paragraphs B1-B37, wherein the method furtherincludes heating the uncured composite structure to cure the uncuredcomposite structure and produce a cured composite structure.

B39. The method of paragraph B38, wherein the heating includes heatingwith a heating device.

B40. The method of any of paragraphs B1-B39, wherein the method furtherincludes cleaning the selected ply carrier.

B41. The method of paragraph B40, wherein the cleaning includes cleaningwith a wash station.

B42. The method of any of paragraphs B1-B41, wherein the method furtherincludes electronically tracking a location of each ply carrier of theplurality of ply carriers.

B43. The method of any of paragraphs B1-B42, wherein the method furtherincludes electronically tracking a structure of at least one ply segmentthat is supported by each ply carrier of the plurality of ply carriers.

B44. The method of any of paragraphs B1-B43, wherein the method furtherincludes uniquely identifying each ply carrier of the plurality of plycarriers.

B45. The method of paragraph B44, wherein the uniquely identifyingincludes at least one of associating a unique bar code with each plycarrier of the plurality of ply carriers and associating a unique radiofrequency identification tag with each ply carrier of the plurality ofply carriers.

B46. The method of any of paragraphs B1-B45, wherein the method furtherincludes maintaining a database of information regarding each plycarrier of the plurality of ply carriers.

B47. The method of any of paragraphs B1-B46, wherein the conveyingincludes conveying with a carrier transfer device.

B48. The method of any of paragraphs B1-B47, wherein the translatingincludes translating at least partially concurrently with the conveying.

B49. The method of any of paragraphs B1-B48, wherein the receiving theselected ply carrier from the carrier transfer device includessupporting the selected ply carrier with the forming machine.

B50. The method of any of paragraphs B1-B49, wherein the receiving theselected ply carrier from the carrier transfer device includes receivingthe selected ply carrier with an end effector of the forming machine.

B51. The method of any of paragraphs B1-B50, wherein the deformingincludes deforming the selected ply carrier and the respective plysegment in a direction that is transverse to a longitudinal axis of theelongate ply forming surface.

B52. The method of any of paragraphs B1-B51, wherein the method includeslocating the respective ply segment between the elongate ply formingsurface and the selected ply carrier during the deforming.

B53. The method of any of paragraphs B1-B52, wherein the deformingincludes compacting the respective ply segment on the elongate plyforming surface.

B54. The method of paragraph B53, wherein the compacting includescompacting with a compaction device of the forming machine.

B55. The method of any of paragraphs B1-B54, wherein the releasingincludes operatively separating the respective ply segment from theselected ply carrier sheet.

B56. The method of any of paragraphs B1-B55, wherein the returningincludes supporting the selected ply carrier with the carrier transferdevice.

B57. The method of any of paragraphs B1-B56, wherein the returningfurther includes returning the selected ply carrier to a/the respectiveply carrier magazine.

B58. The method of any of paragraphs B1-B57, wherein the repeatingincludes selecting both a location within the uncured compositestructure for and a composition of each ply segment of the plurality ofply segments.

B59. The method of any of paragraphs B1-B58, wherein the repeatingincludes incrementally translating the forming machine along the lengthof the forming mandrel a first time to locate a first course ofcomposite material on the elongate ply forming surface and subsequentlyincrementally translating the forming machine along the length of theforming mandrel a second time to locate a second course of compositematerial on the first course of composite material, wherein the firstcourse of composite material includes a first subset of the plurality ofply segments, and further wherein the second course of compositematerial includes a second subset of the plurality of ply segments.

B60. The method of any of paragraphs B1-B59, wherein the repeatingincludes repeating to retain the plurality of ply segments on aplurality of different selected portions of the elongate ply formingsurface.

B61. The method of any of paragraphs B1-B60, wherein the plurality ofply segments includes at least one of a fiberglass, a fiberglass cloth,a carbon fiber, a carbon fiber cloth, a cloth, a pre-impregnated(pre-preg) composite material, a resin material, and/or an epoxy.

As used herein, the terms “selective” and “selectively,” when modifyingan action, movement, configuration, or other activity of one or morecomponents or characteristics of an apparatus, mean that the specificaction, movement, configuration, or other activity is a direct orindirect result of user manipulation of an aspect of, or one or morecomponents of, the apparatus.

As used herein, the terms “adapted” and “configured” mean that theelement, component, or other subject matter is designed and/or intendedto perform a given function. Thus, the use of the terms “adapted” and“configured” should not be construed to mean that a given element,component, or other subject matter is simply “capable of” performing agiven function but that the element, component, and/or other subjectmatter is specifically selected, created, implemented, utilized,programmed, and/or designed for the purpose of performing the function.It is also within the scope of the present disclosure that elements,components, and/or other recited subject matter that is recited as beingadapted to perform a particular function may additionally oralternatively be described as being configured to perform that function,and vice versa. Similarly, subject matter that is recited as beingconfigured to perform a particular function may additionally oralternatively be described as being operative to perform that function.

The various disclosed elements of systems and steps of methods disclosedherein are not required to all systems and methods according to thepresent disclosure, and the present disclosure includes all novel andnon-obvious combinations and subcombinations of the various elements andsteps disclosed herein. Moreover, one or more of the various elementsand steps disclosed herein may define independent inventive subjectmatter that is separate and apart from the whole of a disclosed systemor method. Accordingly, such inventive subject matter is not required tobe associated with the specific systems and methods that are expresslydisclosed herein, and such inventive subject matter may find utility insystems and/or methods that are not expressly disclosed herein.

As used herein, the phrase, “for example,” the phrase, “as an example,”and/or simply the term “example,” when used with reference to one ormore components, features, details, structures, embodiments, and/ormethods according to the present disclosure, are intended to convey thatthe described component, feature, detail, structure, embodiment, and/ormethod is an illustrative, non-exclusive example of components,features, details, structures, embodiments, and/or methods according tothe present disclosure. Thus, the described component, feature, detail,structure, embodiment, and/or method is not intended to be limiting,required, or exclusive/exhaustive; and other components, features,details, structures, embodiments, and/or methods, including structurallyand/or functionally similar and/or equivalent components, features,details, structures, embodiments, and/or methods, are also within thescope of the present disclosure.

1. A composite structure fabrication system, comprising: a plurality ofply carriers, wherein each ply carrier of the plurality of ply carriersdefines a ply support surface configured to temporarily support at leastone ply segment; an elongate forming mandrel that defines an elongateply forming surface, wherein the elongate ply forming surface is shapedto define a surface contour of a composite structure and is configuredto receive a plurality of ply segments to define a plurality of plies ofcomposite material that at least partially defines the compositestructure; a carrier transfer device configured to selectively convey aselected ply carrier of the plurality of ply carriers from a ply kittingarea to an intermediate location; and a forming machine configured toreceive the selected ply carrier at the intermediate location and todeform the selected ply carrier and a respective ply segment over aselected portion of the elongate ply forming surface, separate theselected ply carrier from the respective ply segment such that therespective ply segment is supported by the selected portion of theelongate ply forming surface, and return the selected ply carrier to thecarrier transfer device.
 2. The system of claim 1, wherein the systemfurther includes a plurality of automated ply kitting tools configuredto create the plurality of ply segments, wherein each ply kitting toolof the plurality of automated ply kitting tools is configured to createa respective ply segment of the plurality of ply segments and to operateindependently from a remainder of the plurality of automated ply kittingtools.
 3. The system of claim 1, wherein the system further includes anautomated ply segment locating device configured to locate the at leastone ply segment on each ply carrier of the plurality of ply carriers. 4.The system of claim 1, wherein the system further includes a pluralityof ply carrier magazines, wherein each ply carrier magazine of theplurality of ply carrier magazines is configured to contain a respectivesubset of the plurality of ply carriers.
 5. The system of claim 4,wherein the system further includes an automated magazine transferdevice configured to selectively convey the plurality of ply carriermagazines within the ply kitting area and from a kitting tool area to aply carrier staging area.
 6. The system of claim 1, wherein the carriertransfer device is an automated carrier transfer device.
 7. The systemof claim 1, wherein the carrier transfer device is configured to removethe selected ply carrier from a respective ply carrier magazine.
 8. Thesystem of claim 7, wherein the respective ply carrier magazine islocated in a ply kitting area and the elongate forming mandrel islocated in a ply assembly area, and further wherein the carrier transferdevice is configured to convey the selected ply carrier from the plykitting area to the ply assembly area.
 9. The system of claim 8, whereinthe carrier transfer device includes a pivot structure configured toselectively rotate the selected ply carrier to a horizontal orientationprior to receipt of the selected ply carrier by the forming machine. 10.The system of claim 1, wherein the carrier transfer device is configuredto selectively and sequentially convey a plurality of selected plycarriers of the plurality of ply carriers to the intermediate location,and further wherein the forming machine is configured to selectively andsequentially receive each of the plurality of selected ply carriers andto deform each of the plurality of selected ply carriers at respectivelocations along a length of the elongate forming mandrel.
 11. The systemof claim 1, wherein, subsequent to return of the selected ply carrierfrom the forming machine to the carrier transfer device, the carriertransfer device is configured to return the selected ply carrier to aply carrier magazine.
 12. The system of claim 1, wherein the formingmachine is an automated forming machine, and further wherein the formingmachine includes a forming machine translation device configured toselectively translate the forming machine along a length of the elongateforming mandrel.
 13. The system of claim 1, wherein the system furtherincludes a controller programmed to control operation of at least oneof: (i) the carrier transfer device; (ii) the forming machine; (iii) aply kitting tool; (iv) a ply segment locating device; and (v) a magazinetransfer device.
 14. The system of claim 13, wherein the controller isprogrammed to select a given ply carrier of the plurality of plycarriers for transfer to the intermediate location based, at least inpart, on a structure of the at least one ply segment that is supportedby the given ply carrier.
 15. The system of claim 1, wherein the systemfurther includes a ply carrier tracking system configured toelectronically track a location of each ply carrier of the plurality ofply carriers, wherein the ply carrier tracking system further isconfigured to electronically track a configuration of the at least oneply segment that is supported by each ply carrier of the plurality ofply carriers.
 16. The system of claim 1, wherein the system furtherincludes an uncured composite transfer device configured to selectivelyremove an uncured composite structure, which includes the plurality ofply segments, from the elongate ply forming surface of the elongateforming mandrel.
 17. The system of claim 1, wherein the system furtherincludes a cure mandrel configured to receive an uncured compositestructure subsequent to the uncured composite structure being defined onthe elongate ply forming surface of the elongate forming mandrel. 18.The system of claim 1, wherein the system further includes a heatingdevice configured to heat an uncured composite structure to cure theuncured composite structure and produce a composite structure.
 19. Acomposite structure fabrication system, comprising: a plurality of plycarriers, wherein each ply carrier of the plurality of ply carriersdefines a ply support surface configured to temporarily support at leastone ply segment; an elongate forming mandrel that defines an elongateply forming surface, wherein the elongate ply forming surface is shapedto define a surface contour of a composite structure and is configuredto receive a plurality of ply segments to define a plurality of plies ofcomposite material that at least partially defines the compositestructure; a carrier transfer device; a forming machine; and acontroller programmed to control operation of the carrier transferdevice and the forming machine to: (i) selectively convey, with thecarrier transfer device, a selected ply carrier of the plurality of plycarriers from a ply kitting area to an intermediate location; (ii)transfer the selected ply carrier to the forming machine at theintermediate location; (iii) translate the forming machine along alength of the elongate forming mandrel to a selected location along thelength of the elongate forming mandrel; (iv) deform, with the formingmachine, the selected ply carrier and a respective ply segment, which issupported by the selected ply carrier, over a selected portion of theelongate ply forming surface; (v) release the respective ply segmentfrom the selected ply carrier while retaining the respective ply segmenton the selected portion of the elongate ply forming surface; and (vi)return, with the forming machine, the selected ply carrier to thecarrier transfer device.
 20. A method of fabricating a compositestructure, the method comprising: conveying a selected ply carrier froma ply kitting area to a selected location along a length of an elongateforming mandrel that defines an elongate ply forming surface, whereinthe elongate ply forming surface is shaped to define a surface contourof a composite structure and is configured to receive a plurality of plysegments to define a plurality of plies of composite material that atleast partially defines the composite structure; translating a formingmachine along the length of the elongate forming mandrel to the selectedlocation; receiving the selected ply carrier with the forming machine;deforming, with the forming machine, the selected ply carrier and arespective ply segment, which is supported by the selected ply carrier,over a selected portion of the elongate ply forming surface; releasingthe respective ply segment from the selected ply carrier while retainingthe respective ply segment on the selected portion of the elongate plyforming surface; returning, with the forming machine, the selected plycarrier to the ply kitting area; and repeating the conveying, thetranslating, the receiving, the deforming, the releasing, and thereturning with a plurality of ply carriers, which each supports arespective ply segment, to locate the plurality of ply segments on theelongate ply forming surface and at least partially define an uncuredcomposite structure.
 21. The method of claim 20, wherein the methodfurther includes creating the plurality of ply segments, wherein thecreating includes independently creating a respective ply segment of theplurality of ply segments with each ply kitting tool of a plurality ofautomated ply kitting tools.
 22. The method of claim 21, wherein thecreating includes concurrently creating at least two ply segments of theplurality of ply segments with two different ply kitting tools of theplurality of automated ply kitting tools.
 23. The method of claim 20,wherein the method further includes storing a respective subset of theplurality of ply carriers within each of a plurality of ply carriermagazines.
 24. The method of claim 23, wherein the storing includesstoring at least 2 ply carriers in each of the plurality of ply carriermagazines.
 25. The method of claim 20, wherein the storing includesvertically storing the respective subset of the plurality of plycarriers within each of the plurality of ply carrier magazines.
 26. Themethod of claim 20, wherein the method further includes transferring theuncured composite structure from the elongate ply forming surface of theelongate forming mandrel to a cure mandrel.
 27. The method of claim 20,wherein the method further includes heating the uncured compositestructure to cure the uncured composite structure and produce a curedcomposite structure.
 28. The method of claim 20, wherein the methodfurther includes cleaning the selected ply carrier.
 29. The method ofclaim 20, wherein the method further includes electronically tracking alocation of each ply carrier of the plurality of ply carriers.
 30. Themethod of claim 20, wherein the method further includes electronicallytracking a structure of at least one ply segment that is supported byeach ply carrier of the plurality of ply carriers.
 31. The method ofclaim 20, wherein the method further includes uniquely identifying eachply carrier of the plurality of ply carriers.
 32. The method of claim20, wherein the method further includes maintaining a database ofinformation regarding each ply carrier of the plurality of ply carriers.33. The method of claim 20, wherein the method includes locating therespective ply segment between the elongate ply forming surface and theselected ply carrier during the deforming.
 34. The method of claim 20,wherein the repeating includes selecting both a location within theuncured composite structure for each ply segment of the plurality of plysegments and a composition of each ply segment of the plurality of plysegments.
 35. The method of claim 20, wherein the repeating includesincrementally translating the forming machine along the length of theelongate forming mandrel a first time to locate a first course ofcomposite material on the elongate ply forming surface and subsequentlyincrementally translating the forming machine along the length of theelongate forming mandrel a second time to locate a second course ofcomposite material on the first course of composite material, whereinthe first course of composite material includes a first subset of theplurality of ply segments, and further wherein the second course ofcomposite material includes a second subset of the plurality of plysegments.